System for supporting and leveling paving stones

ABSTRACT

A system of pieces for adding to variable height and variable angle supports made by cutting standard pipe to a desired height for supporting square or rectangular paving stones or other solid materials (pavers) for making a planer surface. The system includes a spacer with spacer vanes for setting spaces between stones and a web that holds the spacer vanes in relationship to each other. The spacer, consisting of the spacer vanes and the web, may sit on a base and engage with the base against any sideways forces, or a section of pipe may be inserted between them with engagement at both ends against sideways forces. The system includes several thicknesses of shims that may be added between the stone and the base or at either end of the pipe.

RELATION TO PREVIOUS APPLICATION

The present application claims priority from U.S. ProvisionalApplication 60/563,861, filed Apr. 19, 2004, which is incorporatedherein by reference.

BACKGROUND

For millennia, stonemasons have paved architectural spaces with slabs ofstone cut to square or rectangular shapes so that they fit closelytogether. Since Roman times, it has been known to place variable heightsupports under the stones so that their top surfaces are level withrespect to each other. The supports can vary in height to accommodate anuneven substrate below the stones or varying thicknesses of the stonesthemselves.

A modern system of plastic support components called the AWS PedestalSystem is marketed by Appian Construction of Seattle, Wash. It includesbases (“bottom caps”) and top caps with vanes, along with cut sectionsof 4 inch PVC pipe, to create supports. Drawbacks of this systeminclude: (1) Base shims attach to the bottoms of the bases, requiringthat the base be lifted and reset to add a shim. (2) Weight from thepaver passes though the structure of the top cap to rest on the top endof the section of pipe, rather than resting directly on the end of thepipe. (3) The spacer vanes are not adapted to be broken off, so the topcap cannot be used to support and provide space between two pavers at amid point along a side of a paver. (4) The top shims are retained by aclose fitting protrusion that interlocks with a hole in the cap, suchthat the shims must be carefully placed or they will be higher thanintended because they have not fully interlocked and then they arelikely to settle if they shift to achieve full interlocking. (5) The topcap and base cannot be used together without a section of pipe; insteadan alternate base must be substituted, which requires an excessivenumber of parts in the kit.

SUMMARY OF THE INVENTION

The invention is a system of variable height and variable angle supportcomponents with integrated spacers for supporting square or rectangularpaving stones or other solid slab materials (pavers) for making a planersurface. In one embodiment, the system includes a spacer with spacervanes for setting spaces between stones and a web that holds the spacervanes in relationship to each other. The spacer, consisting of thespacer vanes and the web, may sit directly on a base, in which case itengages with the base against any sideways forces. In one embodiment,weight of the stone (paver) passes directly to the base. In anotherembodiment, the base supports the spacer which supports the paver.

The base and the spacer are configured so that a section of pipe can becut to a preferred length and angle for a particular corner where stonesmeet and inserted between the base and the spacer. The cut section ofpipe engages both the base and the spacer against sideways forces(horizontal shear forces) while holding them apart from each other bythe preferred distance. The section of pipe can be cut with an angle onone or both ends to accommodate a supporting surface location that isnot level. The pipe may be standard round pipe or may be square pipe.The spacer may be adapted to allow the supported paver to rest directlyon the pipe or it may be adapted to receive the weight of the paver andpass the force through the spacer to the pipe.

For fine adjustment, base-shims may be inserted to sit inside a rim onthe base under the section of pipe. Once the base has been placed, itneed not be disturbed to insert a shim. Also, stone adjustmentquarter-shims may be placed on top of the section of pipe and betweenthe spacer vanes to raise a single stone. The quarter shims interlockwith and grip the spacer vanes to retain the spacers against shearforces. They do not need to be interlocked with a hole in the spacer sothey always provide the correct amount of space and cannot settle.

The spacer is configured with V grooves for breaking off one or morespacer vanes for use at an edge or where the corners of two stones meetthe side of a third stone or where the sides of two adjacent stones needsupport in between their corners.

An alternative embodiment omits the base. That is, the lower cut end ofeach section of pipe rests directly on a supporting surface below andthe spacer sits on top of the pipe to hold the stones in proper placerelative to each other.

These and various other features as well as advantages of the presentinvention will be apparent from a reading of the following detaileddescription and a review of the associated drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a shows a top view of the base.

FIG. 1 b shows a side cross-section, of the base.

FIG. 2 a shows a top view of the spacer with spacer vanes and a web.

FIG. 2 b shows a side view of the spacer with spacer vanes and a web.

FIG. 2 c shows a bottom view of the space with spacer vanes and a web.

FIG. 3 a shows pipe adjustment ring shim top or bottom view.

FIG. 3 b shows a side view of pipe adjustment ring shim.

FIG. 4 a shows a quarter shim top or bottom view.

FIG. 4 b shows a quarter shim side view.

FIG. 5 shows a side view of a cut section of standard pipe.

DETAILED DESCRIPTION

The features of the present invention which are believed to be novel areset forth with particularity in the appended claims. Aspects of theinvention may best be understood by making reference to the followingdescription taken in conjunction with the accompanying drawings. In theseveral figures, like referenced numerals identify like elements.

An embodiment of the base is shown in FIG. 1. FIG. 1 a is a top viewshowing a preferred size with an outer diameter of 133 millimeters andan inter diameter of 88.5 millimeters. At a midpoint between thediameters there is a raised short section of cylinder 3 that retains thespacer or the adjustment pipe against sideways movement relative to thebase. As shown in FIG. 1 b, the height of the short cylinder in oneembodiment is 9.8 millimeters. In one embodiment, the base is made ofinjection molded thermoplastic, such as ABS.

FIG. 2 a shows a top view of the spacer with spacer vanes 6 and a web 7which holds them in relationship to each other. FIG. 2 b shows a bottomview of the spacer wherein the web blocks from view most of the spacervanes. Breaking grooves or notches 12 allow two of the spacer vanes tobe easily broken off.

FIG. 2 c shows a side view of the spacer, including a retaining tab 20,the inner surface of which engages the outer surface of the shortcylinder 3 which is a part of the base to prevent sideways slippage.FIG. 2 c also shows a notch 42 which engages the upper end of a cutpiece of standard pipe when the spacer is supported by a length of pipe.

Like the base, in one embodiment, the spacer is formed of injectionmolded thermoplastic such as ABS.

FIG. 5 shows a side view of a cut section of standard pipe. Thedimensions shown on the drawings for the base and spacer are adapted tostandard American four-inch diameter pipe. The width of the notch 22 isadapted to the standard wall thickness of four-inch PVC pipe. StandardABS four-inch diameter pipe may be used in place of PVC pipe. Thesection of pipe sits inside the short cylinder 3 which is part of thebase and fits into the four notches 22, one notch being in each spacervane of the spacer. If the surface below is not level, the pipe may becut with a matching angle.

For installation, the base is set at the preferred location, thepreferred length of standard pipe is cut and one end is fit into thebase inside the short cylinder 3. The spacer is then placed on top ofthe pipe with the notches 22 engaging the upper rim of the pipe. If thepipe was cut to the preferred length, stones may now be placed. Notethat the weight of each stone is supported by the rim of the pipe ratherthan by the web which connects the spacer vanes. If no section of pipeis used, the weight of the stones is supported by the short cylinder 3of the base.

If the pipe was cut a bit too short, a pipe adjustment ring shim asshown in FIG. 3 may be placed inside the short cylinder 3 underneath thepipe. (If square pipe is used, the shims are also square.) If the cut onthe pipe does not match the angle of the surface underneath the base,the ring shim may be broken at notches 41 in the ring shim to create avariable height support. Then one-half of the ring shim may be used orboth halves may be used with a partial overlap. In one embodiment of thesystem, the ring-shims are produced in two thicknesses, 3 millimetersand 1.5 millimeters. In this embodiment, the ring-shims are made ofinjection molded thermoplastic, which may be ABS.

As an alternative to placing a ring shim beneath the pipe, a quartershim as shown in FIG. 4 may be placed between any two adjacent spacervanes of the spacer. A lip 51 on the quarter shim retains an inner edgeof the spacer vane to restrain the quarter shim against sidewaysmovement relative to the spacer. Each quarter shim includes an arcuatesection of plastic 53 that rests on top of the section of pipe, if it isincluded, or rests on top of the short cylinder 3 if no section of pipeis included. The weight of each stone is carried through the arcuatesection of plastic.

If the stones are of varying thicknesses, different thicknesses ofquarter-shims may be used under each stone. In one embodiment, thequarter-shims are provided in thicknesses of 2.5 millimeters and 1.2millimeters. Two or more quarter-shims may be stacked together toachieve preferred adjustments.

Like the other components, in one embodiment, the ring-shims andquarter-shims are made of injection molded thermoplastic, such as ABS.

The above specification, examples, and details provide a completedescription of the manufacture and use of an embodiment the invention.Since many embodiments of the invention can be made without departingfrom the spirit or scope of the invention, the invention resides in theclaims hereinafter appended which shall not be limited by the abovedescription.

1. A spacer for supporting pavers at variable heights adapted on abottom side for receiving, and receiving support from, a cut end of asection of pipe having the dimension and adapted on a top side forreceiving at least two pavers at edges of the pavers and providing aspacer vane that maintains a space between the pavers, wherein thespacer allows each supported paver to rest on a cut end of pipe.
 2. Thespacer of claim 1 wherein the spacer is adapted for receiving corners ofat least four pavers and includes four spacer vanes that maintain spacesbetween the pavers.
 3. The spacer of claim 1 wherein the spacer isadapted to resist any horizontal shear force between itself and a cutend of a pipe on which it rests.
 4. A set of components for supportingpavers at variable heights, comprising: a. a base adapted for receivingand supporting a cut end of a section of pipe having a dimension, b. aspacer adapted on a bottom side for receiving, and receiving supportfrom, a cut end of a section of pipe having the dimension and adapted ona top side for receiving at least two pavers at edges of the pavers andproviding a spacer vane that maintains a space between the paverswherein the base and the spacer are adapted for receiving each other andbearing weight directly from a paver to the base without an interveningsection of pipe.
 5. The set of components of claim 4 wherein the spacerand the base are adapted to resist any horizontal shear force betweenthem.
 6. A set of components for supporting pavers at variable heights,comprising: a. a base adapted for receiving and supporting a cut end ofa section of pipe having a dimension, b. a spacer adapted on a bottomside for receiving, and receiving support from, a cut end of a sectionof pipe having the dimension and adapted on a top side for receiving atleast two pavers at edges of the pavers and providing a spacer vane thatmaintains a space between the pavers; and c. at least one base shimadapted for inserting between the base and a cut section of pipe.
 7. Theset of components of claim 6 wherein the base shim is round and fitsinside a round rim protruding from a top side of the base.
 8. A set ofcomponents for supporting pavers at variable heights, comprising: a. aspacer adapted on a bottom side for receiving, and receiving supportfrom, a cut end of a section of pipe and adapted on a top side forreceiving at least two pavers at edges of the pavers and providing atleast two spacer vanes that maintain space between the pavers; and b. atleast one quarter shim adapted for inserting under a paver wherein theshim is retained by interlocking with nearest ends of two vanes that areat right angles to each other.
 9. The set of components of claim 8wherein the spacer allows each supported paver to rest on a cut end of apipe or on a shim that rests on a cut end of a pipe.
 10. The set ofcomponents of claim 8 wherein the spacer supports the weight of eachsupported block and transmits that weight to a cut end of a pipe.
 11. Aspacer adapted on a bottom side for receiving and receiving support froma cut end of a section of pipe and adapted on a top side for receivingat least two pavers at edges of the pavers and providing a spacer vanethat maintains a space between the pavers wherein V notches areconfigured to allow at least one spacer vane to be broken off leaving atleast two vanes.
 12. The spacer of claim 11 adapted for receivingcorners of at least four pavers and including four spacer vanes thatmaintain spaces between the pavers.
 13. The spacer of claim 11 whereinthe spacer allows each supported paver to rest on a cut end of a pipe.14. The spacer of claim 11 wherein the spacer supports the weight ofeach supported paver and transmits that weight to a cut end of a pipe.15. The spacer of claim 11 wherein the spacer is adapted for use withround pipe.
 16. The spacer of claim 11 wherein the spacer is adapted foruse with square pipe.
 17. The spacer of claim 11 further comprising aset of components including a shim for bearing weight from the paver tothe pipe.
 18. The set of components of claim 17 wherein the spacer hasfour spacer vanes and the shim is a quarter shim that can be used toshim one of four pavers placed on the spacer.